Compact LED lighting unit for use in camera or video flash applications

Abstract

A compact LED lighting unit, ( 1 ) for camera flash applications, comprising a reflective housing having ( 14 ) having a reflective base ( 15 ) and an open top ( 51 ); an LED ( 10 ) mounted within the reflective housing ( 14 ) and a beam shaping foil stack ( 12 ) provided over the open top of the housing ( 14 ); wherein, the foil stack ( 12 ) comprises first and second microstructured sheets ( 50, 52 ), each having an array of elongate locally parallel ridges ( 41 ) facing away from the LED, wherein the ridges of one sheet locally cross the ridges of the other sheet by an angle in the range 30 to 150 degrees.

The invention claimed is: 
     
       1. A compact LED lighting unit comprising:
 a reflective housing having a reflective base and an open top; 
 an LED mounted within the reflective housing; 
 a phosphor associated with the LED; and 
 an optical beam shaping arrangement over the open top of the housing, 
 wherein the optical beam shaping arrangement comprises first and second microstructured sheets with the second sheet over the first sheet with respect to the reflective base, the first sheet comprising a first structured layer and the second sheet comprising a second structured layer, the structured layers having an array of elongate locally parallel ridges facing away from the LED, and having an apex angle at the peak of each ridge, wherein the ridges of one sheet are crossed with the ridges of the other sheet such that the local crossing angle is between 30 and 150 degrees, 
 wherein the ridges of at least one of the first and second microstructure sheets form a zig-zag pattern, and 
 wherein each LED/optical beam shaping arrangement associated with a respective housing comprises a number of ridges per sheet in about the range of 50 to 1000. 
 
     
     
       2. Alighting unit as claimed in  claim 1 , wherein the apex angle of the first and second structured layers is in the range 70 to 130 degrees. 
     
     
       3. A lighting unit as claimed in  claim 2 , wherein the sum of the apex angles of the first and second structured layers is in the range 170-220 degrees. 
     
     
       4. A lighting unit as claimed in  claim 1 , wherein the first structured layer is in contact with a first material of first refractive index and the second structured layer is in contact with a second material of second refractive index, wherein the material of the first structured layer has a refractive index of between 0.3 and 0.55 greater than the first refractive index and the material of the second structured layer has a refractive index of between 0.3 and 0.55 greater than the second refractive index. 
     
     
       5. A lighting unit as claimed in  claim 4 , wherein the first and second materials comprise:
 air with a refractive index of 1.0; or 
 a glue with a refractive index between 1.3 and 1.6. 
 
     
     
       6. A lighting unit as claimed in  claim 5 , wherein the first and second materials comprise air, the apex angle of the first and second structured layers are in the range 95 to 105 degrees, the combined refractive index of the first and second structured layers is in the range of 2.8 to 2.9 and the refractive index of each structured layer is in the range 1.4 to 1.5. 
     
     
       7. A lighting unit as claimed in  claim 1 , wherein the crossing angle is between 60 and 120 degrees. 
     
     
       8. A lighting unit as claimed in  claim 1 , wherein each microstructured sheet comprises a base layer and the structured layer over the base layer. 
     
     
       9. A lighting unit as claimed in  claim 8 , wherein the base layer comprises polyimide, a heat stabilized PET or a heat stabilized PEN. 
     
     
       10. A lighting unit as claimed in  claim 1 , wherein the first and second structured layers comprise a silicone or a hybrid silicone. 
     
     
       11. A lighting unit as claimed in  claim 1 , wherein the phosphor is provided:
 directly over the LED with an air gap over the phosphor; or 
 filling the housing between the LED and the open top; or 
 as a layer beneath the first microstructured sheet and spaced from the LED. 
 
     
     
       12. A lighting unit as claimed in  claim 1 , comprising a camera flash unit. 
     
     
       13. A mobile portable device comprising a camera optical sensor and a flash unit as claimed in  claim 12 . 
     
     
       14. A camera comprising:
 an optical sensor comprising orthogonal rows and columns of sensor elements; and 
 a camera flash unit as claimed in  claim 12 , wherein the orientation of the ridges of one sheet are angled between 20 and 70 degrees with respect to the row or column directions. 
 
     
     
       15. A camera as claimed in  claim 14 , wherein the orientation of the ridges of one sheet are angled between 30 and 60 degrees with respect to the row or column directions.